Method for assembling a preformed floor and roof structure

ABSTRACT

The prefabricated building structure comprises a series of metal or structural rails and a set of panels. At the installation site, the rails are progressively built into a rectangular grid as the panels are captured by the progressively closing grid, the panels having peripheral grooves interlocked by the rails.

United States Patent [191 Smith et al.

[111 3,919,825 Nov. 18, 1975 METHOD FOR ASSEMBLING A I PREFORMED FLOOR AND ROOF STRUCTURE [76] Inventors: Edward A. Smith, 6641 W. 6th St.,

Los Angeles, Calif. 90048; Robert L. Day, 1518 Grismer St., Burbank,

Calif. 91504 [22] Filed: Nov. 18, 1974 21 Appl. No.; 524,972

Related US. Application Data [62] Division of Ser. No. 381,529, July 23, 1973, Pat. No.

[52] US. Cl. 52/741 [51] Int. Cl. E04B 2/56 [58] Field of Search 52/741, 656, 488, 496,

[56] References Cited UNITED STATES PATENTS 2,970,676 2/1961 Maciunas 52/488 X 3,529,393 9/1970 Wilkins 52/496 X 3,603,628 9/1971 Smits et a1. 52/758 H 3,609,936 10/1971 Toscano 52/741 Primary Examiner-Price C. Faw, Jr.

Attorney, Agent, or Firm-Flam & Flam [57] ABSTRACT The prefabricated building structure comprises a series of metal or structural rails and a set of panels. At the installation site, the rails are progressively built into a rectangular grid as the panels are captured by the progressively closing grid, the panels having peripheral grooves interlocked by the rails.

2 Claims, 9 Drawing Figures US. Patent Nov. 18, 1975 Sheet1of4 3,919,825

US. Patent Nov. 18, 1975 Sheet 2 of4 3,919,825

US. Patent Nov. 18, 1975 Sheet30f4 3,919,825

IIO

1 METHOD FOR ASSEMBLING A PREFORMED I FLOOR AND ROOF STRUCTURE This is a division, of application Ser. No. 381,529, filed 7/23/73, now U.S. Pat. No. 3,881,286.

FIELD OF INVENTION This invention falls in the field of building construction, and more particularly to structural frames for buildings.

BACKGROUND OF THE INVENTION It is now well recognized that economical housing depends upon how much of the structure can be built in the factory and how little of the structure need be completed at the building site. Various modular grid systems have been proposed in the past. In general, these systems are cumbersome and complicated and hence leave much to be desired in terms of economy. For example, the junctions are complicated by mitred joints or the like; the panels require a good deal of labor to attach to the rail frame-work. The primary object of this invention is to provide an extremely simple prefabricate modular frame construction that uniquely utilizes simple connector mechanisms and a novel interfit of the panels with a rectangular grid such that no fasteners are required between the panels and the rails.

SUMMARY OF THE INVENTION In order to accomplish the foregoing object, we provide a unique rail and panel combination whereby these components interfit eachother in a simple and effective manner to form a strong rigid building. Specifically, the panels comprise skins of plywood or the like sandwiching between them a foamed core. A peripheral channel about each panel interfits an intermediate key formed on the companion rail. The rails snap together by the aid of connector structures of the type shown and described in U.S. Pat. No. 3,603,628 to Edward A. Smith, et al of Sept. 7, 1971 entitled FRAME CONNECTOR STRUCTURE. The interior rails comprise companion roll formed halves welded together. The outside or boundary rails comprise a single element corresponding to one of the halves of the interior rails. By judiciously staggering the location of connectors, and by utilizing a system of cross reinforcement a very rigid structure results.

BRIEF DESCRIPTION OF THE DRAWINGS A detailed description of the invention will be made with reference to the accompanying drawings wherein like numerals designate corresponding parts in the several figures. These drawings, unless described as diagrammatic, or unless otherwise indicated, are to scale.

FIG. 1 is a perspective view diagrammatically illustrating a building structure made in accordance with at the corners of a panel, and corresponding to the encircled area 3 of FIG. 2.

FIG. 4 is an elarged vertical sectional view of the floor structure, and showing a pier as well as an outside wall, the sectional plane being indicated by the line 4-4 of FIG. 1.

FIG. 5 is a horizontal sectional view taken along a plane corresponding to line 5-5 of FIG. 4.

FIG. 6 is an enlarged fragmentary view of a connector structure, part of the apparatus being broken away and shown in section.

FIG. 7 is a diagrammatic view illustrating the manner in which rails and panels are assembled to form a roof structure. 7

FIG. 8 is a vertical sectional view illustrating a pitched roof structure made in accordance with the present invention.

FIG. 9 is a vertical sectional view illustrating a flat roof structure made in accordance with the present invention. 7

DESCRIPTION OFTHE PREFERRED EMBODIMENT The following detailed description is of the best presently contemplated mode of carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention since the scope of the invention is best defined by the appended claims.

FIG. 1 illustrates a dwelling having both a roof 10 and a floor 12 utilizing interfitting rail and panel structures made in accordance with the present invention. The floor structure as shown in FIG. 2 comprises a plurality of peripheral rails 14, a series of spaced parallel intermediate rails or girders 16 and a plurality of intermediate rails that function as splines or cross braces 18. The rails 14, 16 and 18 are linked into a generally rectangular gridwork by a series of connectors 20 located at the corners of the array. Connectors may be used to connect sections of long end rails or girders in end to end relationship. The rails are preferably made of rolled steel.

A cluster of connectors is shown in FIG. 3. One of the connectors 20 is attached to the end of the girder section 16 in order to link up continuing, girder section 16 The connector 20 is in the form of a rigid hollow support joined at one end, as by welding, its supporting rail. The connector telescopes into the end of thecompanion rail. The connector support in the present instance is in the form of a channel designed closely to fit the tubular part of the rail.

The rail 16 or 18 comprises halves 22 joined, as by welding, along a medial plane, the halves having outwardly offset channel shaped portions 24 together fonning a rectangular tube. The upper ends 26 of the halves form a narrow upstanding rib. The lower angled ends 28 form with the offset portions 24, longitudinally extending bottom channels on both sides of the rail.

The connectors 20 and 20 extend laterally of the rail or girder 16 to connect with cross braces or rails 18. The connectors have spring detents 30 that engage holes 32 formed in the companion rails whereby a rigid mechanical lock is obtained, and as more particularly described in said U.S. Pat. No. 3,603,628.

The panels interfit the rails to be supported thereby with toleration for dimensional variance, whereas the rails are dimensionally controlled to determine the exact configuration of the floor independently of the panels.

Each panel (See FIGS. 3 and 4) comprises two skin layers of plies 36 and 38 that sandwich between them a plastic foam core 40. internal wooden panel rails 41 form the boundaries of the foam core. The foam core imparts exceptional strength to the composite structure. The edges of the skin or plies 36 and 38 overlie the core 40 and core rails 41 so as to form a peripheral groove 42; that receives the outwardly offset portion 24 of the rail with the top ply abutting the rib 26 and the bottom ply fitting the channel at the bottom of the rail. The groove left above the rib 26 is filled with some suitable caulking 43 (See FIG. 4). top ply 36 is thicker than the lower ply 38. The upper ply is thicker than the rib 26.

The outside rails 14 (FIG. 4) are made of individual rail halves. Drip screeds 44 may be provided to cover the recesses formed by the offset portions 24. The end connectors 46 (FIG. 2) for the rails have half the depth of the connectors in order to provide a flush joint.

At some or all of the floor corners, piers 48 are provided for transferring the load of the building to footings 50 or to a substructure. In the present instance, piers 48 are provided at each interior corner. In order to secure the floor to the corresponding pier, four long spike nails 52 are located at the four exterior corners just outside the intersection of the rail 16 and braces 18.

The floor is assembled by progressively connecting the rails and panels. This can be done in a number of ways. For example, as shown in FIG. 2, the first interior rail 16 may be placed along a line of its piers, using whatever connectors may be necessary to form the entire rail length. The panels 34 may then be inserted and held in position upon placement of the first cross brace 18. The second panel 34 and the second brace 18 may then be positioned. The paralled outside rail 14 is then positioned. The panels and cross braces on the other side of the rail 16 may be positioned in a similar manner. Finally, the perpendicular end rails are placed into position, the transverse rails being flexible laterally to ensure their simultaneous alignment with the corresponding connectors 20 or 46.

FIGS. '7, 8 and 9 illustrate rails and panels used to form a roof structure. The rails are the same as the floor rails except that the 'rails have top flanges 98 (FIG. 8) to interflt the top panel plies, which, in this instance, have the same thickness as the panel plies. Parts of the top flanges may be cut away or omitted in order 4 to facilitate placement of screws for rigidly receiving the top panel.

FIG. 7 diagrammatically illustrates a ridge pole made of two generally back to back end rails 102 (FIG. 8) and a clip or bracket 103. These parts are welded together so that the back to back end rails 102 are inclined to each other in an amount corresponding to the desired pitch of the roof. The ridge pole 100 (FIG. 7) carries connectors designed to fit transverse rails or rafters 104. Intermediate brace rails 106 are provided along with end rails 108. Each roof half is progressively formed by placement of rails, panels, braces and end rails in substantially the same manner as the floor, except that two inclined sections are provided.

The roof sections are nailed to the supporting walls 110 (FIG. 8). Facia boards 112 are provided as required or desired, as well as suitable roofing material 114.

The roof shown in FIG. 9 is similarly formed, but in this instance comprises one composite flat section. Both the floor and the roof have been successfully tested under load.

Intending to claim all novel, useful and unobvious features shown or described, we make the following claims:

1. The process of on site construction of a building section utilizing a series of structural rails of tubular configuration and a set of panels, which comprises:

a. progressively connecting the structural rails into a rectangular grid by the aid of connector structures telescopically received in the tubular portions of the rails;

b. inserting panels into each rectangle before the rectangle is closed by a rail;

c. progressively closing rectangular elements of the grid and thereby interlocking said panels.

2. The process set forth in claim 1 together with the step of laying said rails upon a structural corner support, and including the step of securing said building section to said corner supports by nailing the comers of the panels to said supports independently of said rails. a: 

1. The process of on site construction of a building section utilizing a series of structural rails of tubular configuration and a set of panels, which comprises: a. progressively connecting the structural rails into a rectangular grid by the aid of connector structures telescopically received in the tubular portions of the rails; b. inserting panels into each rectangle before the rectangle is closed by a rail; c. progressively closing rectangular elements of the grid and thereby interlocking said panels.
 2. The process set forth in claim 1 together with the step of laying said rails upon a structural corner support, and including the step of securing said building section to said corner supports by nailing the corners of the panels to said supports independently of said rails. 